WO2015191255A1 - Compositions d'électrode comprenant des additifs carbonés - Google Patents

Compositions d'électrode comprenant des additifs carbonés Download PDF

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Publication number
WO2015191255A1
WO2015191255A1 PCT/US2015/031533 US2015031533W WO2015191255A1 WO 2015191255 A1 WO2015191255 A1 WO 2015191255A1 US 2015031533 W US2015031533 W US 2015031533W WO 2015191255 A1 WO2015191255 A1 WO 2015191255A1
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WIPO (PCT)
Prior art keywords
composition
carbon
weight
activated carbon
carbon black
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PCT/US2015/031533
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English (en)
Inventor
Paolina Atanassova
Aurelien L. DUPASQUIER
Miodrag Oljaca
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Cabot Corporation
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Priority to CN201580031313.6A priority Critical patent/CN106463726A/zh
Publication of WO2015191255A1 publication Critical patent/WO2015191255A1/fr

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
    • H01M4/56—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of lead
    • H01M4/57—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of lead of "grey lead", i.e. powders containing lead and lead oxide
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0404—Methods of deposition of the material by coating on electrode collectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/624—Electric conductive fillers
    • H01M4/625—Carbon or graphite
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/627—Expanders for lead-acid accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/06—Lead-acid accumulators
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • Electrode compositions comprising a lead-containing material and a carbon additive comprising carbon black and activated carbon.
  • the compositions can be incorporated into electrode materials for use in, e.g., lead acid batteries.
  • a variety of applications such as micro-hybrid cars and energy storage require lead acid batteries to operate continuously at Partial State of Charge (PSoC) conditions.
  • PSoC Partial State of Charge
  • hybrid vehicles have high power requirements during ignition, braking, cabin-heating, etc., requiring faster recharge rates of the battery.
  • Future applications may operate at different cycling conditions and charge rates, including motive power and stationary flooded batteries where both increased cycle-life and faster charging capability are desired. Accordingly, there remains a need to develop new electrode materials to meet the ever-increasing battery requirements.
  • One embodiment provides an electrode composition comprising a homogeneous mixture comprising: a lead-containing material and a carbon additive comprising carbon black and activated carbon, wherein: a total amount of the carbon additive ranges from 0.1% to 2% by weight, relative to the total weight of the composition, a ratio of carbon black to activated carbon ranges from 0.1 : 0.9 to 0.5 : 0.5, and the activated carbon has a d 50 particle size distribution ranging from 4 ⁇ to 100 ⁇ , and a pore volume of at least 0.7 cm 3 /g-
  • Another embodiment provides a method of making an electrode composition, comprising: combining a lead-containing material and a carbon additive comprising carbon black and activated carbon, to form a mixture, wherein the carbon black is pre- wetted; adding to the mixture sulfuric acid and water to form a slurry.
  • FIG. 1A is a bar graph showing paste density (g-cm 3 ) for pastes containing different carbon additives versus a control (no carbon additive);
  • FIG. IB is a bar graph showing paste penetration (mm) for pastes containing different carbon additives versus a control (no carbon additive);
  • FIG. 2A is a bar graph showing phase content (wt%) of Pb and PbO for freshly formed NAM samples from anode plates containing different carbon additives versus a control (no carbon additive);
  • FIG. 2B shows XRD spectra of freshly formed NAM samples from anode plates, with the inset showing the PbO peak region;
  • FIG. 3 is a stacked plot of end of charge (EOC, top) and end of discharge (EOD) cell voltage (V) as a function of time for cells made from anodes containing the NAM samples.
  • Electrode compositions comprising a homogeneous mixture comprising a carbon additive comprising carbon black and activated carbon.
  • Electrodes made from these compositions can be used in lead-acid batteries.
  • One embodiment provides an electrode composition comprising a homogeneous mixture comprising: lead-containing material and a carbon additive comprising carbon black and activated carbon, wherein: a total amount of the carbon additive ranges from 0.1% to 2% by weight, relative to the total weight of the composition, a ratio of carbon black to activated carbon ranges from 0.1 : 0.9 to 0.5 : 0.5, and the activated carbon has a d 50 particle size distribution ranging from 4 ⁇ to 100 ⁇ , and a pore volume of at least 0.7 cm 3 /g-
  • PbS0 4 crystallites dissolve to release Pb 2+ ions that undergo electron transfer reactions with the metal surface and form Pb.
  • the opposite occurs during discharge, where Pb is converted back to Pb 2+ , followed by crystallization of PbSC , which can dissolve to provide a source of Pb 2+ ions for another charging cycle.
  • the charging cycle occurs at very high rates such that the electron transfer processes occur at the outer surface of the plates, resulting in buildup of lead sulfate. Because the battery is never fully charged, this results in a reduced amount of lead sulfate that is converted back to lead and large lead sulfate crystals are formed. Such accumulation of lead sulfate can diminish battery performance and ultimately lead to battery failure.
  • both carbon black and activated carbon can increase the surface area of the electrode composition (e.g., a negative active material, NAM).
  • NAM negative active material
  • carbon blacks due to their small particle size can act as a seed layer for lead crystallites growth and lead to reduction of NAM pore size and thus a higher "energetic" lead structure, which facilitates dynamic charge acceptance.
  • activated carbon due to its large particle size has less strong effect on NAM porosity, and can be well connected in the "skeleton" of the NAM.
  • carbon additives in general can increase pore volume, the larger size of activated carbon compared to other additives such as carbon black can enhance this effect.
  • the active carbon can provide a 3-D framework where its larger size can provide a larger contact area for the lead sulfate crystallites, preventing excessive accumulation within the plate.
  • the larger pore volume can also provide higher H 2 S0 4 concentration within the electrode, allowing the supply of H + and HS0 4 " when needed. Electron transfer reactions resulting in PbS0 4 formation can occur over a greater surface area with the 3D network afforded by the activated carbon.
  • One embodiment provides an electrode composition in which at least the lead-containing material and carbon additive are uniformly interspersed with each other. Thus, none of the components of the homogeneous mixture are provided as layers or coatings. In one embodiment, other components of the electrode composition (e.g., BaS0 4 , H 2 S0 ) are uniformly interspersed with the lead-containing material and carbon additive.
  • one embodiment provides an equal or lesser amount of activated carbon with respect to carbon black, e.g., in a ratio ranging 0.1 : 0.9 to 0.5 : 0.5, e.g., a ratio ranging from 0.1 : 0.9 to 0.45 : 0.55, a ratio ranging from 0.1 : 0.9 to 0.4 : 0.6, or a ratio ranging from 0.1 : 0.9 to 0.35 : 0.65.
  • the total amount of the carbon black and activated carbon ranges from 0.1% to 1.9% by weight, relative to the total weight of the composition, e.g., a total amount ranging from 0.1% to 1.8% by weight, from 0.1% to 1.7% by weight, from 0.1% to 1.6% by weight, from 0.1% to 1.5% by weight, from 0.1% to 1.4% by weight, from 0.1% to 1.3% by weight, from 0.1% to 1.2% by weight, from 0.1% to 1.1% by weight, or from 0.1% to 1% by weight, relative to the total weight of the composition.
  • the carbon black is present in an amount ranging from 0.1% to 1% by weight, relative to the total weight of the composition, e.g., an amount ranging from 0.1% to 0.9% by weight, from 0.1% to 0.8% by weight, from 0.1% to 0.7% by weight, from 0.1% to 0.6% by weight, from 0.1% to 0.5% by weight, from 0.1% to 0.4% by weight, from 0.1% to 0.3% by weight, from 0.2% to 1% by weight, from 0.2% to 0.9% by weight, from 0.2% to 0.8% by weight, from 0.2% to 0.7% by weight, from 0.2% to 0.6% by weight, from 0.2% to 0.5% by weight, from 0.2% to 0.4% by weight, or from 0.2% to 0.3% by weight, relative to the total weight of the composition.
  • the activated carbon is present in an amount ranging from 0.1% to 1% by weight, relative to the total weight of the composition, e.g., an amount ranging from 0.1% to 0.9% by weight, from 0.1% to 0.8% by weight, from 0.1% to 0.7% by weight, from 0.2% to 1% by weight, from 0.2% to 0.9% by weight, from 0.2% to 0.8% by weight, from 0.2% to 0.7% by weight, from 0.3% to 1% by weight, from 0.3% to 0.9% by weight, from 0.3% to 0.8% by weight, from 0.3% to 0.7% by weight, from 0.4% to 1% by weight, from 0.4% to 0.9% by weight, from 0.4% to 0.8% by weight, from 0.4% to 0.7% by weight, from 0.5% to 1% by weight, from 0.5% to 0.9% by weight, from 0.5% to 0.8% by weight, or from 0.5% to 0.7% by weight, relative to the total weight of the composition.
  • the activated carbon is particulate, e.g., the activated carbon has an aspect ratio (length/diameter) of e.g., 10 or less, 5 or less, or 3 or less.
  • the activated carbon has a d 50 particle size distribution ranging from 4 ⁇ to 50 ⁇ , e.g., a d 50 particle size distribution ranging from 4 ⁇ to 20 ⁇ , or from 4 ⁇ to 10 ⁇ m.
  • the activated carbon itself has a pore volume of at least 1 cm 2 /g, e.g., at least 1.5 cm 2 /g.
  • Activated carbon and high surface area carbon blacks can act as a super capacitor due to double layer formation on its micro porous surface. Supercapacitive effect is proportional to the nitrogen adsorption surface area and could contribute to improved charge acceptance at short time duration (few seconds).
  • the activated carbon has a surface area ranging from 650 m 2 /g to 3000 m 2 /g, e.g., from 650 m 2 /g to 2500 m 2 /g, from 650 m 2 /g to 2000 m 2 /g, from 1000 m 2 /g to 3000 m 2 /g, from 1000 m 2 /g to 2500 m 2 /g, from 1000 m 2 /g to 2000 m 2 /g, from 1200 m 2 /g to 3000 m 2 /g, from 1200 m 2 /g to 2500 m 2 /g, or from 1200 m 2 /g to 3000 m 2 /g.
  • the activated carbon is obtained by
  • the activated carbons disclosed herein are lignite-based activated carbons or bituminous coal- based activated carbons (e.g., derived from lignite or bituminous coal).
  • the carbon black has a surface area ranging from 50 m 2 /g to 2000 m 2 /g, e.g., from 100 m 2 /g to 1500 m 2 /g. In another embodiment the carbon black has a surface area ranging from 100 m 2 /g to 500 m 2 /g, e.g., from 100 m 2 /g to 400 m 2 /g, or from 100 m 2 /g to 300 m 2 /g.
  • the carbon black has a surface area ranging from 100 m 2 /g to 300 m 2 /g and the activated carbon has a surface area ranging from 650 m 2 /g to 2000 m 2 /g, e.g., from 1000 m 2 /g to 2000 m 2 /g or from 1200 m 2 /g to 2000 m 2 /g.
  • the carbon black has a pore volume of at least 0.2 g/cm 3 , e.g., a pore volume ranging from 0.2 g/cm 3 to 2 g/cm 3 .
  • the homogeneous mixture further comprises an organic molecule expander.
  • Organic molecule expander as defined herein is a molecule capable of adsorbing or covalently bonding to the surface of a lead-containing species to form a porous network that prevents or su bstantially decreases the rate of formation of a smooth layer of PbS0 4 at the surface of the lead-containing species.
  • the organic molecule expander has a molecular weight greater than 300 g/mol.
  • Exemplary organic molecule expanders include lignosulfonates, lignins, wood flour, pulp, humic acid, and wood products, and derivatives or decomposition products thereof.
  • the expander is selected from lignosulfonates, a molecule having a su bstantial portion that contains a lignin structure.
  • Lignins are polymeric species comprising primarily phenyl propane groups with some number of methoxy, phenolic, sulfur (organic and inorganic), and carboxylic acid groups.
  • lignosulfonates are lignin molecules that have been sulfonated.
  • Typical lignosulfonates include the Borregard Lignotech products U P- 393, U P-413, U P-414, U P-416, U P-417, M, D, VS-A (Vanisperse A), Vanisperse-HT, and the like.
  • Other useful exemplary lignosulfonates are listed in, "Lead Acid Batteries", Pavlov, Elsevier Pu blishing, 2011, the disclosure of which is incorporated herein by reference.
  • the organic molecule expander is present in an amount ranging from 0.05% to 1.5% by weight, e.g., from 0.2% to 1.5% by weight, or from 0.3% to 1.5% by weight, relative to the total weight of the electrode composition.
  • the lead-containing material is selected from lead, PbO, leady oxide, Pb ⁇ O ⁇ , Pb20, and PbS04, hydroxides, acids, and metal complexes thereof (e.g., lead hydroxides and lead acid complexes).
  • lead-containing material comprises leady oxide.
  • the homogeneous mixture further comprises BaS0 4 .
  • the electrode composition is an aqueous slurry.
  • the homogeneous mixture is a porous solid.
  • curing the aqueous slurry can form the porous solid.
  • the porous solid and has a surface area of at least 4 m 2 /g, e.g., at least 5 m 2 /g-
  • Another embodiment comprises an electrode comprising the compositions disclosed herein (e.g., a solid homogeneous mixture disclosed herein).
  • the electrode can be an anode and can be incorporated into a lead acid battery.
  • Another embodiment provides a method of making a composition, comprising: combining a lead-containing material and a carbon additive comprising carbon black and activated carbon, to form a mixture, wherein the carbon black is pre- wetted; adding to the mixture sulfuric acid and water to form a slurry.
  • the composition is an electrode composition.
  • the carbon additive is present in an amount ranging from 0.1% to 2% by weight, relative to the total weight of the composition.
  • the slurry (e.g., a paste) is dried.
  • the drying is achieved by a slow cure, such as under controlled humidity conditions and a moderate amount of heat (e.g., from 30 to 80°C or from 35 to 60°C) under controlled humidity, resulting in a porous solid.
  • the curing step can then followed by a second heating step (drying) at an elevated temperature (e.g., from 50 to 140°C or from 65 to 95°C) at extremely low humidity, or even zero humidity.
  • the composition is a monolith.
  • Other pasting, curing, and formation procedures are described in "Lead Acid Batteries," Pavlov, Elsevier Publishing, 2011, the disclosure of which is incorporated herein by reference.
  • the slurry (e.g., a paste) is deposited (or otherwise pasted) onto a substrate, such as a plate or grid and allowed to dry on the substrate, where the drying can be performed as disclosed herein.
  • the plate or grid is a metallic structure that come in a myriad of designs and shapes (e.g., punched or expanded from sheets), functioning as the solid permanent support for the active material.
  • the grid also conducts electricity or electrons to and away from the active material.
  • Grids can comprise pure metals (e.g., Pb) or alloys thereof.
  • the components of those alloys can comprise Sb, Sn, Ca, Ag, among other metals described in "Lead Acid Batteries," Pavlov, Elsevier Publishing, 2011, the disclosure of which is incorporated herein by reference.
  • the electrode is formed when the cured material that is deposited on the plate is subjected to a charging process.
  • this process can comprise immersing the cured, deposited material in a tank containing an H 2 S0 4 solution and charging the material from 120% to 400% of theoretical capacity for a period of time, e.g., at least 2h, e.g., from 2h to 25h.
  • electrode compositions comprising a homogeneous mixture comprising an electroactive material (e.g., the lead-containing material) and a carbon additive.
  • the mixture is in the form of a paste, e.g., a negative paste.
  • NAM negative active material
  • the carbon additive can comprise, consist essentially of, or consist of carbon black and activated carbon in the amounts and proportions disclosed herein.
  • Such electrode compositions can be deposited on conducting substrates to form an electrode (e.g., an anode) that can be incorporated in a cell, e.g., a lead-acid battery.
  • This Example describes the preparation of anode materials containing various carbon additives including carbon black alone, and mixtures of carbon black + graphite, and carbon black + activated carbon.
  • CB additives PBXTM 51, PBXTM 09, and PBXTM 135 additives, Cabot Corporation
  • AC activated carbon
  • EG expanded graphite
  • ABGTM 1010 graphite Superior Graphite
  • PBX101 AC has a d 50 particle size distribution of 4.5 ⁇ .
  • Negative pastes with different carbon materials and concentrations were produced and lead-acid cells were assembled.
  • Pastes were produced at a 1 kg batch size using 1.40 g cm "3 H 2 S0 4 and leady oxide (75% degree of oxidation) at a ratio equal to 6.0 wt%.
  • the pastes were prepared by dry mixing 1 kg leady oxide (2 min) then adding 2 g Vanisperse A lignosulfonate, 8g barium sulfate, and carbon additives and mixed for 5 min. All carbon black additives were pre-wetted prior to being added to the mixture, whereas PBX101 activated carbon and ABG 1010 expanded graphite were used without pre-wetting. Water ( 130 m L) was added and mixed for 8 min, followed by addition of 80 mL 1.4 g/cc sulfuric acid and mixing for 20 min. Additional water was added when needed at the end of the mixing.
  • FIGs. 1A and IB show the negative paste density (g-cnrf 3 ) and paste penetration (mm) as determined for the different paste samples (having different carbon additives) in comparison to a control sample with no carbon additive. Although paste density was slightly lower than the control, adjustment in water content resulted in similar consistency as evidenced by penetration depth, and resulting in good pasting a bility.
  • the negative plates were made of lead Pb-0.04 Ca-1.10 Sn alloy and had grid dimensions of 57 mm x 60 mm x 1.5 mm.
  • the coated plates had a thickness of 2.5 mm. Curing was done for 72 hours at 35°C and 98% relative humidity, followed by 24 hours at 60°C and 10% relative humidity.
  • the coated negative electrodes were formed by a tank formation process by using 1.06 g cm "3 H 2 S0 4 solution and charging to 400% of theoretical capacity for 25h.
  • the formed plates were characterized by XRD and were similar to control. As shown in FIG.
  • FIG. 2A shows XRD spectra of the NAM samples, with the inset showing the PbO peaks.
  • the PBX51-containing sample provided the highest PbO peak in the XRD whereas the lowest PbO peak arose from the control.
  • the increased levels of PbO may be related to the formation of smaller lead crystallites and consecutively to higher surface area of lead exposed to air and moisture causing higher degree of oxidation upon exposure to ambient conditions.
  • NAM surface areas were measured by BET nitrogen adsorption, and NAM pore area, pore size volume and pore size were measured by mercury porosimetry
  • This Example describes testing on cells containing the anodes of Example 1.
  • the above described cycling schedule comprised one cycling unit of the accelerated cycling test.
  • the total time duration of one cycling unit was 32 h.
  • the cell voltage was measured during the cycling, and the test was stopped when the end-of- discharge cell voltage fell below 1.70 V.
  • FIG. 3 is a stacked plot of end of charge (EOC, top) and end of discharge (EOD) cell voltage (V) as a function of time for cells made from anodes containing the NAM samples, indicating the cell cycle life.
  • EOC end of charge
  • EOD end of discharge
  • V cell voltage
  • Expanded graphite ABGIOIO (1%) showed similar cycle life of 28 units. Even higher cycle life was achieved for a cells with mixture of carbon black PBX135 (0.5%) and ABGIOIO (1%), which at 36 units was more than a 2 x improvement compared to the control. The highest cycle life (47 units) was observed for the cell with the mixture of PBX135 (0.5%) and PBXIOI (1%), or approximately 3x improvement versus the control.
  • Carbon black additives in the negative plates leads to a modification of negative plate morphology and affects the average pore diameter.
  • Carbon black additive with highest surface area (PBX51) has the strongest impact on the NAM morphology, charge acceptance and cycle life compared to intermediate surface area carbon blacks (PBX09, PBX135).
  • Combinations of intermediate surface area carbon black (PBX135) and activated carbon (PBXIOI) leads to significant improvement of cycle life, up to 3x compared to the control, and greater than the mixture of carbon black with expanded graphite.

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Abstract

L'invention concerne des compositions d'électrode comprenant un mélange homogène comprenant : un matériau contenant du plomb et un additif carboné comprenant du noir de carbone et du charbon actif. Une quantité totale de l'additif carboné va de 0,1 % à 2 % en poids par rapport au poids total de la composition. La composition peut avoir un rapport noir de carbone sur charbon actif allant de 0,1 : 0,9 à 0,5 : 0,5. Le charbon actif peut avoir une distribution de taille de particules d50 allant de 4 µm à 100 µm, et un volume de pores d'au moins 0,7 cm3/g. L'invention concerne également des électrodes formées à partir de la composition d'électrode, des piles (par exemple, des batteries au plomb-acide) comprenant les électrodes/compositions d'électrode, ainsi que leurs procédés de fabrication.
PCT/US2015/031533 2014-06-10 2015-05-19 Compositions d'électrode comprenant des additifs carbonés WO2015191255A1 (fr)

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